Extruded Structural Beam

ABSTRACT

An extruded structural beam having a first member comprising rigid webbing interposed between a top flange and bottom flange. The top and bottom flanges of the first member each have a groove formed thereon for receiving a spline to secure screening material. Similarly, a second member having rigid webbing interposed between a top flange and bottom flange have a groove formed on the flanges for receiving a spline to secure screening material. The top and bottom flanges of both the first member and second member each further comprise opposing longitudinal channels for coupling the flanges so that a rectangular structural beam is formed. The outer surfaces of the flanges each further comprise a longitudinal slot so that a plurality of fasteners can be installed, through the longitudinal slots and flanges to secure the first member and second member together.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to structural beams, and morespecifically to using a novel means of assembly and flange design toincrease the strength, of a structural beam.

2. Description of the Prior Art

It is common for lightweight aluminum alloy beams to be used toconstruct the framework for a screened pool enclosure. The beams aretypically assembled in the field from two separate members to form ahollow box beam. The distance that the aluminum beam can span over anopen space without additional support is determined by the thickness, orgauge, of the aluminum. Another factor is dimensions of the beam.Although a beam with a larger cross section provides additional,strength and can span larger distances, a disadvantage to a larger beamis that it is not aesthetically pleasing, is heavy in weight making itmore difficult to work with in the field and more expensive.

There have been attempts to improve the prior art aluminum alloy beamsto increase the strength without increasing the size and weight of thebeams. However, one shortcoming of the prior art is that there is nointerlocking relationship between the two separate members. Therefore, aweakness of the prior art beams is that the fasteners securing theflanges of the two members together are subject to high tension, whichmay cause the beam to fell under load. Accordingly, what is needed inthe art is a beam that has interlocking flanges to increase the strengthof the beam and to reduce the tension on the fasteners and possibilityof local buckling.

Another need exists in the art for the two separate members of the beamto act as one unit and to decrease the likelihood of local bucklingunder design loads.

Another need exists in the art for a beam that increases span distancesover the standard legacy beam shape in the industry.

Another need exists in the art for a structural beam that that islightweight and easy to assemble in the field.

Another need exists in the art for an improved structural beam whereinthe wall thickness of the beam is variable to meet deflection criteriain foe local, and state building codes.

It is, therefore, to the effective resolution, of the aforementionedproblems and shortcomings of the prior art that the present invention isdirected.

However, in view of the prior art at the time the present invention wasmade, it was not obvious to those of ordinary skill in the pertinent arthow the identified needs could be fulfilled.

SUMMARY OF THE INVENTION

This invention is an extruded structural beam comprising a first memberhaving a first webbing interposed between a first top flange and a firstbottom flange wherein said first top flange is disposed perpendicular tosaid first webbing and parallel to said first bottom flange; said firsttop flange having a longitudinal channel formed on a first lower surfaceof said first fop flange; said top flange having a first upper surfacefurther comprising a first upper groove formed thereon for receiving afirst upper spline; said first bottom flange having a longitudinalchannel formed on a first lower surface of said first bottom flange; andsaid bottom flange further comprising a first lower groove for receivinga first lower spline; a second member having a second webbing interposedbetween a second top flange and a second bottom flange wherein saidsecond top flange is disposed perpendicular to said second webbing andparallel to said second bottom flange; said second top flange furthercomprising a longitudinal channel formed on a second lower surface ofsaid second top flange; said top flange having a second upper surfacefurther comprising a second upper groove formed thereon for receiving asecond upper spline; said second bottom flange having a longitudinalchannel formed on a second lower surface of said second bottom flange;and said second bottom flange further comprising a second lower groovefor receiving a second lower spline; said longitudinal channel of saidfirst top flange removably coupled to said longitudinal channel of saidsecond top flange and said longitudinal channel of said first bottomflange is removably coupled to said longitudinal channel of said secondbottom flange so that a rectangular structural beam is formed; saidfirst upper surface of said fop flange of said first member furthercomprising an upper longitudinal slot so that a plurality of fastenerscan be installed through said upper longitudinal slot and through saidtop flange of said second member to secure said top flange of said firstmember and said top flange of said, second member.

The improved structural beam provides increased strength of the beamthrough a novel means of assembly and flange design that when assembledhas three overlying flange layers. The invention allows for greaterspans to be bridged by the new beam using the assembly of two separatemembers with the new flange configuration that can be easily cut andjoined together in the field thereby improving ease of installation andreducing costs. The trademark name for this invention is suggested to bethe “Triple Flange Beam.”

It is therefore a primary object of the invention to provide an improvedstructural beam that will be used in the construction of aluminum screenenclosures.

Another object of the present invention is to employ similar aluminumalloys that are used in the construction of aluminum screen enclosures.

Another object of the present invention is to provide an improvedstructural beam wherein, the wall thickness of the beam is variable tomeet deflection criteria in the local and state building codes.

Another object of the present invention is to provide an improvedstructural beam that has interlocking flanges to increase the strengthof the beam.

Another object of the present invention is to provide an improvedstructural beam with two separate members that act as one unit and todecrease the likelihood of local buckling under design loads.

Another object of the present invention is to provide an improvedstructural beam that increases span distances over the standard legacybeam shape in the industry.

Another object of the present invention is to provide an improvedstructural beam that is lightweight and easy to assemble in the field.

These and other important objects, advantages, and features of theinvention will become clear as this description proceeds.

The present invention, accordingly, comprises the features ofconstruction, combination of elements, and arrangement of parts thatwill be exemplified in the description set forth hereinafter and thescope of the invention will be indicated in the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

For a fuller understanding of the nature and objects of the invention,reference should be made to the following detailed description, taken inconnection with, the accompanying drawings, in which;

FIG. 1 is a partial perspective view showing a first embodiment of thebeam of the present invention as assembled;

FIG. 2 is a cross sectional view showing a first embodiment of the beamof the present invention;

FIG. 3 is a cross sectional view showing a first member of the beam, inthe first embodiment of the present invention;

FIG. 4 is a partial perspective view showing a second embodiment of thebeam of the present invention as assembled;

FIG. 5 is a cross sectional view showing a second embodiment of the beamof the present invention;

FIG. 6 is an exploded cross sectional, view showing a first member andstrut of the beam in a second embodiment of the present invention;

FIG. 7 is a partial perspective view showing a third embodiment of thebeam of the present invention as assembled;

FIG. 8 is a cross sectional view showing a third embodiment of the beamof the present invention as assembled;

FIG. 9 is an exploded cross sectional view showing a first member andstrut of the beam in the third embodiment of the present invention;

FIG. 10 is a partial perspective view showing a fourth embodiment of thebeam of the present invention as assembled;

FIG. 11 is a cross sectional view showing a fourth embodiment of thepresent invention as assembled; and

FIG. 12 is an exploded cross sectional view showing a first member andstrut of the beam in the fourth embodiment of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

FIG. 1 shows the new beam 100 is comprised of a first member 130 and asecond member 120. The beam 100 is shown assembled to form a rectangularhollow shape. Each member is a standard beam shape that is used inconstruction, of screen enclosures and extruded through a die process tovarious lengths. First member 130 and second member 120 are assembled inthe field to form the new structural beam 100. The materials used tomake beam 100 are the same aluminum alloys that are used in theconstruction of aluminum, screen enclosures. The wall thickness of firstmember 130 and second member 120 will vary between each size change andare dependant on code requirements to meet deflection criteria in thelocal and state building codes.

Referring now to FIG. 2 and FIG. 3, a cross section of the beam 100 isshown including the coupling of the flanges. A longitudinal slot 125 ontop flange 150 and longitudinal slot 127 on bottom, flange of secondmember 120 show where screws are used to secure first member 130 andsecond member 120 together. An architectural groove 129 is provided onbottom, flange of second member 120 and an architectural groove 132 isprovided on the top flange of first member 130 that mirrors the groovethat is formed when the top flanges and bottom flanges are assembledtogether.

A rigid webbing 135 interconnects upper flange 150 and lower flange 140.In cross sectional view, the first member is generally C-shaped. Alongitudinal channel 142 is formed on the lower surface of the bottomflange 140. Channel 142 allows for the opposing lower flange of thesecond member 120 to be inserted therein and be coupled together.Similarly, channel 152 is adaptable so that top flange of second member120 is coupled to top flange 150 of first member 130. As beam 100 ismanufactured, for the aluminum screen enclosure industry, groove 154 isformed in top flange 150 to receive a spline (not shown) used, to securescreening material therein.

In the preferred embodiment the structural beam is screwed together withfasteners on the top flange 150 and bottom flange 140 using sheet metalscrews. A longitudinal slot is provided on the top flange 150 of firstmember 130 and on the bottom flange of second member 120 for thelocation of the fasteners. A key difference between the prior art andthe present invention is that the tension load on the screws is greatlyreduced by the novel design of the flanges of the present invention.Accordingly, the screws have higher efficacy in preventing the firstmember and second member from being pulled apart under a load. When beam100 is assembled, the flanges of first member 130 and second member 120are overlying one another and form three layers for superior strengthquality of beam 100.

Referring now to FIG. 4 shows a second embodiment of beam 400 assembledwith first member 430 and second member 420. A first planar strut 510 isinserted to first member 430 and a second planar strut 520 is insertedto second member 420. FIG. 5 and FIG. 6 show the cross section of beam400. A rigid webbing 435 interconnects upper flange 450 and lower flange440. Top flange 450 and bottom flange 440 of first member 430 areidentical to top flange 150 and bottom flange 140 of beam 100. Thedifference is the addition of planar struts 510, 520, which provideadditional strength and resistance to the buckling of beam 400 underloads. FIG. 6 shows how planar strut 510 is inserted to first member430, which is identical to die procedure to insert planar strut 520 tosecond member 420. Planar strut 510 includes a small top flange 550 matis positioned adjacent to the lower surface of top flange 450 of firstmember 430. A small bottom flange 540 of planar strut 510 is positionedadjacent to the upper surface of bottom flange 440 of first member 430.An upper protrusion 555 and lower protrusion 575 on planar strut 510engages an opposing upper protrusion 455 and lower protrusion 475 on theinside surface of first member 430. In addition, a track is interposedon planar stmt 510 between upper protrusion 555 and lower protrusion 575to engage a T-shape projection on first member 430. Once planar strut510 is secured to first member 430, the procedure is repeated to insertplanar strut 520 to second member 420. First member 430 and secondmember 420 are then assembled using top flange 450 and bottom flange440, which comprise longitudinal channels 452, 442, respectively, andgrooves 454, 444 for receiving a spline to secure screening material.

Referring now to FIG. 7 shows a third embodiment of beam 700 assembledwith first member 730 and second member 720. Similar to the second,embodiment described above, a first planar strut 810 is inserted tofirst member 730 and a second planar strut 820 is inserted to secondmember 720. FIG. 8 and FIG. 9 show the cross section of beam 700. Arigid webbing 735 interconnects upper flange 750 and lower flange 740.Top flange 750 and bottom flange 740 of first member 730 are identicalto top flange 150 and bottom flange 140 of beam 100. The difference isthe addition of planar struts 810, 820, which provide additionalstrength and resistance to the buckling of beam 700 under loads. Thedifference between the second embodiment and the present embodiment isthe attachment means of planar struts 810, 820 to first member 730 andsecond member 720, respectively. FIG. 9 shows how planar strut 810 isinserted to first member 730, which is identical to the procedure toinsert planar strut 820 to second member 720. Planar strut 810 includesa small top flange 850 that is positioned adjacent to the lower surfaceof tap flange 750 of first member 730, A small bottom flange 840 ofplanar strut 810 is positioned adjacent to the upper surface of bottomflange 740 of first member 730. An upper track 855 and lower track 875on planar strut 810 engages an opposing upper T-shape protrusion 755 andlower protrusion 775 on the inside surface of first member 730. Inaddition, a track is interposed on planar stmt 810 between upper track855 and lower track 875 to engage an opposing shape protrusion on firstmember 730. Once planar strut 810 is secured to first member 730, theprocedure is repeated to insert planar strut 820 to second member 720.First member 730 and second member 720 are then, assembled using topflange 750 and bottom flange 740, which comprise longitudinal channels752, 742, respectively, and grooves 754, 744 for receiving a spline tosecure screening material.

Referring now to FIG. 10 shows a fourth embodiment of beam 900 assembledwith first member 930 and second, member 920. Similar to die second andthird embodiments described above, a first planar strut 910 is insertedto first member 930 and a second planar strut 915 is inserted to secondmember 920. FIG. 11 and FIG. 12 show the cross section of beam 900. Arigid webbing 935 interconnects upper flange 950 and lower flange 940.Top flange 950 and bottom flange 940 of first member 930 are identicalto top flange 150 and bottom flange 140 of beam 100. The difference isthe addition of planar struts 910, 915, which provide additionalstrength, and resistance to the buckling of beam 900 under loads. Thedifference between the second and third embodiment and the presentembodiment is the attachment means of planar struts 910, 915 to firstmember 930 and second member 920, respectively. FIG. 12 shows how planarstmt 910 is inserted to first member 930, which is identical to theprocedure to insert planar strut 915 to second member 920. Planar stmt910 includes a small top flange 980 that is positioned adjacent to thelower surface of top flange 950 of first member 930. A small bottomflange 990 of planar strut 910 is positioned adjacent to the uppersurface of bottom flange 940 of first member 930. An upper protrusion957 and lower protrusion 977 on planar strut 910 engages an opposingupper protrusion 955 and lower protrusion 975 on the inside surface offirst member 930. Once planar strut 910 is secured to first member 930,the procedure is repeated to insert planar strut 915 to second member920. First member 930 and second member 920 are then assembled using topflange 950 and bottom flange 940, which comprise longitudinal channels952, 942, respectively, and grooves 954, 944 for receiving a spline tosecure screening material.

The particular embodiments disclosed above and in the drawings areillustrative only, as the invention may be modified and practiced indifferent but equivalent manners apparent to those skilled in the arthaving the benefit of the teachings herein. Furthermore, no limitationsare intended to the details of construction or design herein shown. Itis therefore evident that die particular embodiments disclosed above maybe altered, or modified and all such variations are considered withinthe scope and spirit of the invention.

It is also to be understood that the following claims are intended tocover all of the generic and specific features of the invention hereindescribed, and all statements of the scope of the invention, which as amatter of language, might be said to tall there between.

Now that the invention has been described,

1. An extruded structural beam comprising: a first member having a firstwebbing interposed between a first top flange and a first bottom flangewherein said first top flange is disposed perpendicular to said firstwebbing and parallel to said first bottom flange: said first top flangehaving a longitudinal channel formed on a first lower surface of saidfirst top flange; said top flange having a first upper surface furthercomprising a first upper groove formed, thereon for receiving a firstupper spline; said first bottom flange having a longitudinal channelformed on a first lower surface of said first bottom flange; and saidbottom flange further comprising a first lower groove for receiving afirst lower spline; a second member having a second webbing interposedbetween a second top flange and a second bottom flange wherein saidsecond top flange is disposed perpendicular to said second webbing andparallel to said second bottom flange; said second top flange furthercomprising a longitudinal channel formed on a second lower surface ofsaid second top flange; said top flange having a second upper surfacefurther comprising a second upper groove formed thereon for receiving asecond upper spline; said second bottom flange having a longitudinalchannel formed on a second lower surface of said second bottom flange;and said second bottom flange further comprising a second lower groovefor receiving a second lower spline; said longitudinal channel of saidfirst top flange removably coupled to said longitudinal channel of saidsecond top flange and said, longitudinal channel of said first, bottomflange is removably coupled to said longitudinal channel of said secondbottom flange so that a rectangular structural beam is farmed.
 2. Thestructural beam of claim 1 wherein said first member and said secondmember are extruded through a die process to a pre-determined length. 3.The structural beam of claim 1, wherein said first upper surface of saidtop flange of said first member further comprising an upper longitudinalslot so that a plurality of fasteners can be installed through saidupper longitudinal slot and through said top flange of said secondmember to secure said top flange of said first member and said fopflange of said second member.
 4. The structural beam of claim 1, whereinsaid second lower surface of said bottom flange of said second memberfurther comprising a lower longitudinal slot so that a plurality offasteners can be installed through said lower longitudinal slot andthrough said bottom flange of said first member to secure said bottomflange of said first member and said bottom flange of said secondmember.
 5. The structural beam of claim 1, wherein said first member andsaid second member are comprised of an aluminum alloy.
 6. The structuralbeam of claim 1, wherein said structural beam is of hollow construction.7. The structural beam of claim 1, wherein said first member and saidsecond member form a standard beam shape that is commonly used in theconstruction of aluminum structures.
 8. The structural beam of claim 1,further comprising a first planar strut wherein said first planar stmthaving a first upper longitudinal strut projection adjacent to an outersurface of said first planar strut.
 9. The structural beam of claim 8,wherein said first planar strut having a first lower longitudinal strutprojection adjacent to said outer surface of said first planar strut.10. The structural beam of claim 9, wherein said first planar strutfurther comprising a first track interposed between said first upperlongitudinal strut projection and said first lower longitudinal strutprojection on said outer surface of said first planar strut.
 11. Thestructural beam of claim 10, wherein said first member furthercomprising a first upper longitudinal member projection adjacent to aninner surface of said first member so that said first upper longitudinalprojection engages said first upper longitudinal strut projection. 12.The structural beam of claim 11, wherein said first member furthercomprising a first lower longitudinal member projection adjacent to aninner surface of said first member so that said first lower longitudinalprojection engages said first lower longitudinal strut projection. 13.The structural beam of claim 12, wherein said first member farthercomprising a first T-shaped projection interposed between said firstupper longitudinal member projection and said lower longitudinal memberprojection so that said first T shaped projection engages said firsttrack on said outer surface of said first planar strut.
 14. Thestructural, beam of claim 13, further comprising a second planar strutwherein said second planar strut having a second upper longitudinal,strut projection adjacent to an outer surface of said second planarstrut.
 15. The structural beam of claim 14, wherein said second planarstrut having a second lower longitudinal, strut projection, adjacent tosaid, outer surface of said second planar strut.
 16. The structuralbeam, of claim 15, wherein said second planar strut farther comprising asecond track interposed between said second upper longitudinal strutprojection and said second lower longitudinal strut projection on saidouter surface of said second planar strut.
 17. The structural beam ofclaim 16, wherein said second member further comprising a second upperlongitudinal member projection adjacent to an inner surface of saidsecond member so that said second upper longitudinal projection engagessaid second upper longitudinal strut projection.
 18. The structural beamof claim 17, wherein said second member further comprising a secondlower longitudinal member projection, adjacent to an inner surface ofsaid second member so that said second lower longitudinal projectionengages said second lower longitudinal strut projection.
 19. Thestructural beam of claim 18, wherein said second member furthercomprising a second T-shaped projection interposed between said secondupper longitudinal member projection and said lower longitudinal memberprojection so that said second T-shaped projection engages said secondtrack on said outer surface of said second planar strut.
 20. Thestructural beam of claim 1, further comprising a first planar strutwherein, said first planar strut having a first upper strut trackadjacent to an outer surface of said first planar strut.
 21. Thestructural beam of claim 20, wherein said first planar stmt having afirst lower strut track adjacent to said outer surface of said firstplanar strut.
 22. The structural beam of claim 21, wherein said firstplanar strut further comprising an intermediate strut track interposedbetween said first upper strut track and said first lower strut track onsaid outer surface of said first, planar strut.
 23. The structural beamof claim 22, wherein said first member further comprising a first upperT-shaped projection adjacent to an inner surface of said first member sothat said first upper T-shaped projection engages said first upper strutback.
 24. The structural beam of claim 23, wherein said first memberfurther comprising a first lower T-shaped projection adjacent to aninner surface of said first member so that said first lower T-shapedprojection engages said first lower strut track.
 25. The structural beamof claim 24, wherein said first member further comprising anintermediate T-shaped, projection interposed between said first upperT-shaped projection and said first lower T-shaped projection so thatsaid intermediate T-shaped projection engages said first intermediatestrut track on said outer surface of said, first planar strut.
 26. Thestructural beam of claim 25, further comprising a second planar strutwherein said second planar strut having a second upper strut trackadjacent to an outer surface of said second planar strut.
 27. Thestructural beam of claim 20, wherein said second planar strut having asecond lower strut track adjacent to said outer surface of said secondplanar strut.
 28. The structural beam of claim 21, wherein said secondplanar strut further comprising an intermediate strut track interposedbetween said second upper strut track and said second lower strut trackon said outer surface of said second planar strut.
 29. The structuralbeam of claim 22, wherein said second member further comprising a secondupper T-shaped projection adjacent to an inner surface of said secondmember so that said second upper T-shaped projection engages said secondupper strut track.
 30. The structural beam of claim 23, wherein saidsecond member further comprising a second lower T-shaped projectionadjacent to an inner surface of said second member so that said secondlower T-shaped projection engages said second lower strut track.
 31. Thestructural beam of claim 24, wherein said second member furthercomprising an intermediate T-shaped projection interposed between saidsecond upper T-shaped projection and said second lower T-shapedprojection so that said intermediate T-shaped projection engages said,second intermediate strut track on said outer surface of said secondplanar strut.
 32. The structural beam of claim 1, further comprising afirst planar strut wherein said first planar stmt having a first upperlongitudinal strut projection adjacent to an outer surface of said firstplanar strut.
 33. The structural beam of claim 32, wherein said firstplanar strut having a first lower longitudinal strut projection adjacentto said outer surface of said first planar strut.
 34. The structuralbeam of claim 33, wherein said first member further comprising a firstupper longitudinal member projection adjacent to an inner surface ofsaid first member so that said first upper longitudinal projectionengages said first upper longitudinal strut projection.
 35. Thestructural beam of claim 34, wherein said first member furthercomprising a first lower longitudinal member projection adjacent to aninner surface of said first member so that said first lower longitudinalprojection engages said first lower longitudinal strut projection. 36.The structural beam of claim 35, further comprising a second planarstrut wherein said second planar strut having a second upperlongitudinal strut projection adjacent to an outer surface of saidsecond planar strut.
 37. The structural beam of claim 36, wherein saidsecond planar strut having a second lower longitudinal strut projectionadjacent to said outer surface of said second planar strut.
 38. Thestructural beam of claim 37, wherein said second member furthercomprising a second upper longitudinal member projection adjacent to aninner surface of said second member so that said second upperlongitudinal projection engages said second upper longitudinal strutprojection.
 39. The structural beam of claim 38, wherein said secondmember further comprising a second lower longitudinal member projectionadjacent to an inner surface of said second member so that said secondlower longitudinal projection engages said second lower longitudinalstrut projection.